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Vanguard OHV V-Twin User Manual

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272144 - Vanguard V-Twin
For Briggs & Stratton Discount Parts Call 606-678-9623 or 606-561-4983
To go to the beginning of each section,
click below.
To go back to Table of Contents, click on
"Bookmark" to the left
SAFETY, MAINTENANCE AND ADJUSTMENTS
ENGINE SPECIFICATIONS

TABLE OF CONTENTS

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Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Section 7
Section 8
Section 9
Section 10
Section 11
Section 12
Section 13

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Summary of Contents for Vanguard OHV V-Twin

  • Page 1: Table Of Contents

    272144 - Vanguard V-Twin For Briggs & Stratton Discount Parts Call 606-678-9623 or 606-561-4983 To go to the beginning of each section, TABLE OF CONTENTS click below. To go back to Table of Contents, click on "Bookmark" to the left SAFETY, MAINTENANCE AND ADJUSTMENTS .
  • Page 2 Section 1 Safety, Maintenance and Adjustments Page AIR CLEANER SERVICE ............. Round Air Cleaner .

  • Page 3: In The Interest Of Safety

    IN THE INTEREST OF SAFETY CAUTION indicates a hazard that, if not avoided, might result in minor or moderate injury. DANGER CAUTION when used without the alert symbol, in- dicates a situation that could result in damage to FOLLOW INSTRUCTIONS the engine.
  • Page 4 WARNING WARNING Gasoline and its vapors are extremely flammable and explosive. Kerosene and its vapors are Fire or explosion can cause severe extremely flammable, and should burns or death be handled with the same WHEN ADDING FUEL precautions as gasoline. •...
  • Page 5 WARNING WARNING Rotating parts can contact or Engines give carbon entangle hands, feet, hair, clothing, monoxide, an odorless, colorless, or accessories. poison gas. Traumatic amputation or severe Breathing carbon monoxide can laceration can result. cause nausea, fainting or death. • Start and run engine outdoors. •...
  • Page 6 Additional Precautions (Use only Briggs & Stratton approved tools and proce- dures to remove the flywheel.) Before working on the engine, read and understand DO NOT operate engine without a muffler. (Inspect the applicable sections of this manual. Follow all periodically and replace if worn or leaking.

  • Page 7: Briggs & Stratton Numerical Identification System

    BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM YOUR KEY TO THE WORLD'S FINEST ENGINES BRIGGS & STRATTON MODEL NUMBERING SYSTEM FIRST DIGIT SECOND DIGIT THIRD DIGIT FOURTH DIGIT AFTER DISPLACEMENT AFTER DISPLACEMENT AFTER DISPLACEMENT AFTER DISPLACEMENT PTO BEARING, REDUCTION GEAR, CUBIC INCH BASIC CRANKSHAFT AUXILIARY DRIVE,...

  • Page 8: Fuel And Oil Recommendations

    FUEL & OIL RECOMMENDATIONS Gaseous Fuel Engines DANGER Fuel Recommendations AVOID INJURY! Gaseous fuel systems should only be worked on in a very well ventilated area. Gasoline Engines • Many state, county and city governments • Use clean, fresh regular unleaded gasoline with a require that service be performed ONLY minimum of 85 octane.

  • Page 9: Oil Recommendations

    Old oil gradually thickens and loses its cooling ability and its lubricating qualities. Air cooled engines run hotter than automotive Briggs & Stratton OHV V-Twin engines are lubri- engines. Use of multi-viscosity oils (10W-30, etc.) in ambient temperatures above 405 F cated with a gear-driven oil pump.

  • Page 10: Air Cleaner Service

    AIR CLEANER SERVICE Ì Ì Ì Ì WARNING AVOID FIRES! • Never operate an engine with the air cleaner „ assembly or air cleaner cartridge removed! … ƒ A properly serviced air cleaner protects internal en- ‚ gine parts from airborne dirt and dust particles. If air cleaner instructions are not followed, particles that ...

  • Page 11: Square Air Cleaner

    Cyclonic Air Cleaner CAUTION: DO NOT use petroleum solvents to clean paper cartridge. DO NOT oil paper cartridge. NOTE: The debris valve automatically discharges DO NOT use pressurized air to clean or dry paper dust and debris. There should be minimal cartridge.

  • Page 12: Armature Air Gap Adjustment

    CARBURETOR ADJUSTMENTS  Models 290000 – 350000 ‚ The Vanguardt OHV twin cylinder engine carbure- tor fuel mixture adjustment procedure is unique. Per- form adjustments exactly in the sequence shown. NOTE: If engine is equipped with Performance Controlt electronic governor see separate adjustment procedure.
  • Page 13 ‚   Ì Ì Ì Ì Ì Ì † ‚ ƒ … „ Fig. 8 Fig. 10 4. Turn idle mixture screw slowly CLOCKWISE (1) until engine speed just starts to slow (LEAN Final Adjustment mixture), Fig. 11. All carburetor adjustments performed with the en- gine running must be made with the air cleaner installed.

  • Page 14: Performance Controle Engines

    ˆ „ … ‰ Š Fig. 12 Fig. 14 Performance ControlE Engines 10. If the carburetor is equipped with an idle mixture limiter cap install it at this time. NOTE: All carburetor adjustments with engine running must be made with the air cleaner a.

  • Page 15: Models 351400, 380400, 351700, 380700

    NOTE: Idle speed may vary according to OEM  specifications. Ì Ì Ì Ì Ì Ì Ì Ì Ì Ì Ì Ì … ƒ ‚ „ Fig. 16 8. Deactivate idle-down device, or remove jumper wire. Engine should accelerate smoothly to top governed speed.
  • Page 16 4. While holding throttle lever, SLOWLY turn idle a. 1750 RPM – Governed Idle Spring #805453 mixture screw for #1 cylinder CLOCKWISE until (RED). engine speed just starts to slow (LEAN mixture). b. 1100 RPM – Governed Idle Spring #805454 (WHITE).

  • Page 17: Choke Control Adjustment

    All Except Models 540000, 610000 Fig. 24 Fig. 25 shows the blower housing removed and 1. Place choke control lever on equipment in areas to be cleaned (1) on the Vanguard engine. CHOKE position. 2. Loosen control casing clamp screw (4). ...

  • Page 18: Crankcase Oil

    Models 540000, 610000 1. Use a coin or screwdriver to twist the Easy Clean Accesst panel fasteners (1), Fig. COUNTERCLOCKWISE until a CLICK is heard (approx. 3/4 turn). 2. Remove the panel (2). Ì Ì Ì Ì Ì Ì Ì ...

  • Page 19: Governor Adjustments

    The crankcase capacity of Vanguardt V-Twin CAUTION: Do not bend governor link or distort engines is approximately: governor lever. • All (except Model 540000) – 48 oz. (1.4 liters) with filter • Models 540000, 610000 – 79 oz. (2.3 2. Use a screwdriver (2) to rotate governor shaft COUNTERCLOCKWISE as far it will go.
  • Page 20 Fixed Speed Adjustable – Except Generators Governor spring is installed in #1 hole in governor lever (3), Fig. 35. Start and run engine for approximately 5 minutes to allow engine to warm up. 1. Turn fixed speed adjustable control nut counter- clockwise until control swivel contacts slow speed stop.
  • Page 21 5. Turn fixed speed adjustable control nut (6) Adjust Secondary Governor Spring clockwise (8) to increase or counter-clockwise 1. Disengage the adjustable fixed speed control (7) to decrease engine speed until desired Top nut (Inset, Fig. 40). No-Load RPM is obtained, Fig. 37. 2.
  • Page 22 (6) to obtain RPM shown, Fig. 43: Secondary Governor Spring a. 1750 RPM – Governed Idle Spring #805453 Some Vanguard OHV V-Twin engines with remote speed control are equipped with a secondary gover- (RED). nor spring (5). The primary governor spring is b.

  • Page 23: Oil Cooler

     ˆ †  Fig. 43 Fig. 45 Oil Cooler Some engines are equipped with an oil cooler, 7. With equipment control lever in SLOW position Fig. 46. The oil cooler is mounted on the blower and engine running at governed idle RPM, use housing.

  • Page 24: Speed Control Wire Adjustment

      Fig. 47  All Except Models 540000, 610000 FAST Resistor spark plugs recommended by Briggs & Stratton: SLOW • B&S #491055 (Champion RC12YC) or Fig. 48 • B&S #496018 (Champion RC14YC) Valve Clearance Adjustment Gap to 0.030” (0.76 mm). 1.

  • Page 25: Overhaul Procedure

    TUNE-UP PROCEDURE A “Tune-Up,” see the steps listed below, would normally be performed on relatively new engines brought in for minor difficulties. By performing these steps you will either be sure that the engine is functioning properly or will know what major repairs should be made. The steps are also covered in the Overhaul Procedure and will normally be performed as a part of the complete overhaul.

  • Page 26: Inspection And Repairs

    23. Cylinder – check cylinder bores and bearings. 7. Electric starter. Remove oil seal. 8. Flywheel and starter pulley (if equipped). 24. Disassemble and check connecting rods, 9. Armatures – adjust air gap. pistons, piston pins and rings. 10. Check spark. 25.

  • Page 28: Troubleshooting

    Section 2 Troubleshooting Page ELECTRICAL SYSTEMS ............Alternators .

  • Page 29: Systematic Check

    Most complaints concerning engine operation can be  classified as one or more of the following:  1. Will not start 2. Hard starting 3. Lack of power 4. Runs rough ‚ ‚ 5. Vibration 6. Overheating 7. High oil consumption NOTE: What appears to be an engine problem may actually be the fault of the powered equipment.

  • Page 30: Carburetion

    Fouled Plug or Dead Cylinder If plugs are dry, look for – To test for a fouled spark plug or a non-functioning 1. Leaking carburetor mounting gaskets cylinder, attach Ignition Tester #19368 (2) between 2. Gummy or dirty carburetor, fuel line or tank the spark plug lead (1) and each spark plug (4).
  • Page 31 Cylinder Leakdown Test Use a leakdown tester to test the sealing capability ‚ of each cylinder. Follow the instructions for the leak- down tester you are using to determine the likely problem area(s). 1. Run engine for 5 minutes allowing engine to reach operating temperature.
  • Page 32 Conclusion: Cylinder #1 is weaker cylinder.  NOTE: A partially sheared flywheel key will affect ‚ ignition timing and engine performance. „ Problems Affecting One Cylinder NOTE: A two cylinder engine will run on one cylinder as long as the power required for the application does not exceed the power produced by one cylinder.

  • Page 33: Electrical Systems

    ELECTRICAL SYSTEMS Alternators Alternator System Diagnosis The following list is provided to help diagnose alternator system problems. COMPLAINT POSSIBLE CAUSES • Engine RPM too low. • Inline fuse “blown” (if equipped). • Defective battery. • Loose, pinched, or corroded battery ground leads. •...

  • Page 34: Charging System Identification

    Charging System Identification Table No. 1 provides a means of identifying the various alternator systems. The alternator systems installed on Briggs & Stratton OHV V-Twin Cylinder Engines can be identified by the color of the stator output wires and the connector.

  • Page 35: Flywheel Magnet Identification

    Flywheel Magnet Identification Equipment Used to Test Alternators Digital Multimeter NOTE: Does NOT include engines with the Power- Linkt system. The Digital Multimeter #19464, Fig. 8, is available from your Briggs & Stratton source of supply. The Digital Multimeter can be used to read volts, ohms, The V-Twin flywheels have a ring of magnets (1) on amperes, and to test diodes.

  • Page 36: Testing Alternator Output

    Testing Alternator Output  ‚ When testing alternators, perform the tests in the following sequence. NOTE: Before testing alternator output, use an accurate tachometer to temporarily adjust the engine speed to the RPM specified in the test instructions. ƒ 1. Test alternator output. Fig.

  • Page 37: Dc Alternator

    DC Alternator 7. If NO or LOW output is found, test diode. The DC alternator provides DC current for charging a 12 volt battery. The current from the alternator is  unregulated and is rated at 3 amps. The output rises from 2 amps @ 2400 RPM, to 3 amps @ 3600 RPM.

  • Page 38: Dual Circuit Alternator

    ƒ ‚   † „ … ƒ ‚ Fig. 15 Fig. 14 DC Output Test NOTE: The battery MUST be in good condition to NOTE: Service replacement diode harnesses are perform this test. available. Use resin core solder when 1.

  • Page 39: Tri-Circuit Alternator

    Diode Test AC Output Test 1. Insert RED test lead into VW receptacle in meter. In the DIODE TEST position, the meter will display the forward voltage drop across the diode(s). If the 2. Insert BLACK test lead into COM receptacle. voltage drop is less than 0.7 volts, the meter will 3.
  • Page 40 The battery is not used for the lights, so lights are available even if the battery is disconnected or removed. Current for the lights is available when the engine is running. The output varies with engine RPM, so the brightness of the lights changes with engine speed.

  • Page 41: 5 & 9 Amp Regulated Alternator

    ‚ ƒ ƒ  ‚  Fig. 21 Fig. 22 5 & 9 Amp Regulated Alternator The 5 & 9 amp regulated alternator systems provide current through single lead Lighting Circuit Test (WHITE Wire) regulator-rectifier. The regulator-rectifier converts the AC current to DC and regulates current to the battery. The charging rate will vary with engine RPM and 1.

  • Page 42: 16 Amp Alternator

    Output Test Connect stator wire harness to regulator-rectifier. 1. Insert RED test lead into 10A receptacle in WHEN CHECKING ALTERNATOR COMPONENTS meter. MAKE TESTS IN THE FOLLOWING SEQUENCE: 2. Insert BLACK test lead into COM receptacle. Temporarily disconnect stator wire harness from regulator-rectifier.
  • Page 43 • 2. Two BLACK leads (2) from stator. 20 Volts – 10 Amp System • 30 Volts – 16 Amp System 3. YELLOW connector (3) with two pin terminals. 6. If NO or LOW output is found check for bare 4.

  • Page 44: 20 Amp Regulated Alternator

    7. If NO or LOW output is found, be sure that 20 Amp Regulated Alternator regulator-rectifier is grounded properly and all The 20 amp regulated alternator system provides AC connections are clean and secure. If there is still current through output leads output,...
  • Page 45 4. Attach RED (2) and BLACK (1) test lead probes 7. If meter does not display battery voltage, check to the YELLOW wire (4) AC output terminals (6), for blown fuse or broken or shorted wires. of the connector (3), as shown in Fig. 31. (Meter test clip leads may be attached to either AC out- Regulator-Rectifier Test put terminal.)

  • Page 46: Powerlink System

    POWERLINK SYSTEM 4. If the power goes OFF the GFCI is working correctly. Press the reset button to restore power. Some V-Twin engines are equipped with the Power- LinktSystem, an on-board generator system for NOTE: Use only approved GFCI riding tractors that provides 120 volt, 60 cycle AC to components.
  • Page 47 4. Test for continuity between the inverter case and the GFCI ground.  There should be CONTINUITY in Step 3 and Step 4. If there is NO CONTINUITY a problem exists in the ground circuit. ‚ Fig. 36 Testing PowerLinkt Reset Switch Digital Multimeter #19464 is used for this test.

  • Page 48: Anti-Afterfire Solenoid

    If the previous tests have not revealed a faulty 6. Press button on test box and note AC voltage. component it is necessary to check the alternator Alternator output should be NO LESS THAN 100 output. If the alternator output is within specification Volts.

  • Page 49: Testing Battery

    Testing Battery Test Equipment Digital Multimeter #19464. WARNING The following tests will be performed with the meter in the V== (DC volts) position, Fig. 40. Batteries contain ACID which is poisonous and causes severe burns. Avoid contact with skin, eyes or clothing.
  • Page 50 Installation b. Fill battery cells with distilled water after charging (for batteries that have been in 1. Before installing battery, connect all equipment service). to be operated. See typical wiring diagram, Fig. 42. NOTE: If battery gets HOT to the touch, or is spitting acid (gassing) excessively, unplug charger 2.

  • Page 51: Testing Engine Wiring Harness

    Testing Engine Wiring Harness A jumper wire is required for this test. Make sure key switch is OFF before connecting The engine wiring harness consists of a ground wire jumper wire. (1) with a diode (4) for each armature (5) and a sepa- rate wire (2) for the carburetor solenoid, Fig.
  • Page 52 3. Attach BLACK test lead to a good ground, Fig. 47. 4. Turn key switch to ON position. Meter should display battery voltage. If meter does not display battery voltage, replace engine wiring harness. If meter displays battery voltage, test the solenoid. ...
  • Page 53 ENGINE WIRING HARNESS DIAGRAM GROUND WIRE HARNESS CARBURETOR SOLENOID DIODE DIODE ENGINE HARNESS ENGINE HARNESS CONNECTOR RAISED RIB ON CONNECTOR INDICATES EQUIPMENT HARNESS CONNECTOR GROUND SIDE EQUIPMENT SWITCH DIODE FAILURE DIAGNOSIS SWITCH ON SWITCH OFF CAUSE Engine Runs Shuts Off OK 1 Closed Diode On 1 Cylinder Only One Cylinder...

  • Page 54: Oil Pressure

    Oil Pressure  Test Switch Use Digital Multimeter #19464. Set meter to test for continuity. Remove pressure switch. Connect one tester lead to the switch terminal and the other lead to the metal body of the switch, Fig. 48. The tester should indicate CONTINUITY when no pressure is applied Fig.
  • Page 55 NOTE: Terminals #1, #3 and #6 are grounded to key switch case when key switch is OFF. Meter must indicate CONTINUITY between these terminals and the key switch case when key switch is OFF. When testing RUN and START terminals, meter should show CONTINUITY between terminals, with key switch in position shown.
  • Page 56 Wiring Diagram For Starter Panel & Key Switch For V-Twin Engines Terminal No. Wire Color Function Not Used White To Carburetor Solenoid (when used) Black To Stop Switch Terminal On Engine Yellow To Solenoid (tab terminal) Orange To Battery (battery terminal on solenoid) To Regulator/Rectifier STOP ANTI-AFTERFIRE...

  • Page 57: Starter Motor

    Starter Motor Starter Motor Spins But Does Not Crank Engine a. Sticking pinion gear due to dirt. Conditions Affecting Starter Motor Performance b. Damaged pinion or ring gear. 1. Bound or seized starter motor bearings. c. Starter clutch slipping. d. Battery faulty or damaged. 2.

  • Page 58: Solenoid Test

    6. Insert BLACK test lead into COM receptacle in „ meter. ƒ 7. Rotate meter selector to + )) (DIODE TEST) ‚ position. 8. Attach one meter test lead to each stud terminal on solenoid (2, 3), Fig. 52. 9. Attach one end of jumper lead to POSITIVE †...

  • Page 59: Performance Controle Electronic Governor

    PERFORMANCE CONTROL The Performance Control electronic governor  control system consists of an electronic control ELECTRONIC GOVERNOR module, wiring and stop switch harness and a Some V-Twin engines are equipped with the throttle actuator. The control module is equipped Performance Control electronic governor system with an idle-down circuit for applications requiring for generator or welder applications.

  • Page 60: Governor Test

    Governor Test Static Check To determine whether a governor problem is being caused by the actuator or the control module, Dynamic Check perform the following static check exactly in order shown. Perform dynamic check exactly in order shown. A pair of jumper wires and a known good 12 volt 1.
  • Page 61 2. Remove air cleaner assembly. a. Torque four 8mm screws to 150 in. lbs. (17 Nm). 3. Disconnect governor link at carburetor. b. Torque two 6mm screws to 70 in. lbs. 4. Remove governor control bracket with actuator. (10 Nm). 5.

  • Page 62: Gaseous-Fueled Engines

    GASEOUS FUELED ENGINES TROUBLESHOOTING GUIDE Symptom Potential Cause Action Plugged vent ports on the regulator. Remove plastic shipping plugs. Adjust the primary regulator output to 11 Less than 11 inches of water inches of water pressure. pressure at the inlet of the If natural gas supply is lower than 11 secondary regulator.
  • Page 63 TROUBLESHOOTING GUIDE (CONTINUED) Out of fuel. Refuel the tank. Fuel supply shut off. Open fuel tank. Check for proper operation of all fuel lock-off (safety) devices. Filter or vacuum lock off is not If electrically actuated, check for dead battery or blown fuse. Engine will not start.

  • Page 64: Carburetor Adjustment

    GASEOUS FUEL CARBURETOR  ADJUSTMENT Some Briggs & Stratton V-Twin engines were available factory-built to operate on liquefied petroleum gas (LPG) or natural gas (NG). To maintain the California Air Resource Board (CARB) emissions certification on these engines, the ‚ Original Equipment Manufacturer (OEM) must use specific equipment and procedures to complete the ƒ...

  • Page 65: Equipment Problems Affecting Engine Operation

    EQUIPMENT PROBLEMS AFFECTING ENGINE OPERATION Frequently, what appears to be an engine problem 2. Check for loose or disconnected equipment stop may be the fault of the equipment powered rather switch wire. than the engine itself. Since many types of equipment 3.

  • Page 66: Engine Disassembly

    Section 3 Engine Disassembly Page AFTER DISASSEMBLY ............. . ENGINE DISASSEMBLY .

  • Page 67: Parts Identification

    PARTS IDENTIFICATION AIR CLEANER BASE ROTATING SCREEN CARBURETOR COVER BLOWER HOUSING INTAKE MANIFOLD AND CARBURETOR CHOKE BRACKET AIR CLEANER SUPPORT EXHAUST MANIFOLD GOVERNOR LEVER GOVERNOR CONTROL BRACKET VALLEY COVER CYLINDER SHIELDS VALVE COVERS...
  • Page 68 #2 CYLINDER HEAD #1 CYLINDER HEAD FLYWHEEL AND FAN ALTERNATOR ARMATURES BACKPLATE STARTER MOTOR BREATHER CRANKCASE COVER OR SUMP CAMSHAFT AND GOVERNOR SPOOL #2 PISTON AND CONNECTING ROD ASSEMBLY #1 PISTON AND CONNECTING ROD ASSEMBLY CRANKSHAFT VALVES CYLINDER...

  • Page 69: Engine Disassembly

    ENGINE DISASSEMBLY „ Preparation … • Drain oil. Remove and discard oil filter. † • Disconnect choke and throttle control cables. • Remove engine from equipment. • Remove spark plugs. • Remove muffler and exhaust manifold. Remove Air Cleaner Assembly ‡...

  • Page 70: Horizontal Crankshaft - Models 351400-380400

      ‚ ‚ Fig. 4 Fig. 6 Horizontal Crankshaft – Models 351400 – 380400 Remove Blower Housing and Fan 1. Remove air cleaner cover, cartridge and pre- cleaner. 1. Remove blower housing (1) and debris screen (2), Fig. 7. 2.

  • Page 71: Remove Carburetor And Intake Manifold

    Remove Carburetor and Intake Manifold 2. Disconnect choke link (1) from carburetor. 3. Disconnect fuel line at carburetor. Vertical Crankshaft, All Models 4. Disconnect governor link and spring (4) from 1. Remove air cleaner assembly. retainer (3) and throttle lever (2). 2.

  • Page 72: Remove Flywheel

    „ †  Fig. 13 Fig. 15 Flywheel – All Models EXCEPT Engines with Remove Flywheel PowerLinkt Flywheel Nut – Models 290000, 303000, 540000, NOTE: See the special procedure at the end of this 610000 section for flywheel removal on engines with 1.

  • Page 73: Flywheel Nut - Powerlinke

    Flywheel – Models WITH PowerLinkt CAUTION AVOID HAND AND/OR FINGER INJURY! • The flywheel magnets are VERY POWERFUL and can rapidly draw the flywheel to the engine. Exercise caution and use the proper tools when servicing the flywheel. Fig. 18 Required Tools 5.

  • Page 74: Remove Breather And Starter Motor

    Remove Breather and Starter Motor „ 1. Remove breather (3), alternator (6), backplate (5) and starter motor (4), Fig. 20. ‚ ƒ „  … ƒ Fig. 22 3. Remove head bolts (5, 6, 7, 8) and cylinder † head, Fig. 23. Discard cylinder head gasket. NOTE: Engines manufactured before 940501xx Fig.

  • Page 75: After Disassembly

    Remove Pistons and Connecting Rods NOTE: Remove any carbon or ridge at the top of cylinder bores to prevent breaking rings ‚ when removing piston and connecting rod assemblies.  1. Remove #2 connecting rod cap. ƒ 2. Push connecting rod and piston assembly (11) out of #2 cylinder (arrow), Fig.

  • Page 76: Fuel Systems And Carburetion

    Section 4 Fuel Systems and Carburetion Page CARBURETION ..............Carburetor Identification .

  • Page 77: Fuel Systems

    FUEL SYSTEMS 7 Quart Fuel Tank † † Removal 1. Remove air cleaner knob (1) and cover (2), Fig. 1. 2. Remove air cleaner nut (3), top plate (4) and † † element (5). Fig. 2 8. If necessary remove 4 screws and 2 PTO side fuel tank base supports (7), Fig.

  • Page 78: 9-Quart Fuel Tank

    9 Quart Fuel Tank NOTE: Install the supports over the governor control bracket, one side at a time to avoid disturbing the governor adjustment. Install Removal the screws in the same order as removed. 1. Remove air cleaner cover knobs (1) and cover (2), Fig.

  • Page 79: Fuel Pump

    5. Lift the fuel tank. Disconnect the fuel hose from All Except Models 540000, 610000 the carburetor fuel inlet (6), Fig. 10. Remove the The fuel pump is actuated by pulsating crankcase fuel valve shut-off knob from the shut-off link (7). vacuum from the engine.

  • Page 80: Carburetion

    Carburetor Identification Fig. 13 Three types of carburetors are used on gasoline Early (8) and current (9) style fuel filter assemblies Vanguard OHV V-Twin engines: for Vanguardt engines with the 9 quart fuel tank • One-piece Flo-Jet side-draft on Models shown in Fig.
  • Page 81  ‚ ƒ ‡ Fig. 16 Fig. 18 5. Remove air cleaner elbow support screw (8), Fig. 19. 6. Remove 3 intake elbow screws and carburetor assembly. Models 351400 and 380400 7. Remove carburetor spacer (10) and gaskets (9). The blower housing must be removed so that anti- ˆ...

  • Page 82: Carburetor Service

    NOTE: The inspection in Step 2 is performed after the carburetor has been disassembled. 2. Inspect throttle shaft and choke shaft for wear (2), Fig. 22. ‚ Fig. 22 Replace either shaft if worn. Replace the carburetor if the body is worn or if either shaft clearance exceeds 0.010”...
  • Page 83 8. Remove the idle mixture screw (12). † Fig. 24 Fig. 27 4. Remove fixed main jet (7) using Screwdriver #19062, Fig. 25. 9. The top and bottom edges of the throttle plate 5. Reach into carburetor throat with flat blade are beveled.
  • Page 84 Ô Ô Ô Ô Î Î Î Î Ô Ô Ô Ô Ô Ô Fig. 30 Fig. 32 Ô Ô Ô Ô Ô This completes carburetor disassembly procedure. 13. Remove screw (25) and choke plate (24), Clean Carburetor Fig. 31. 1.
  • Page 85 NOTE: Do not use wire, drills or other mechanical 8. Install new throttle shaft welch plug. Use round devices to clean out metering holes or punch and tap in plug until it is flat. passages. 9. Use sealant on outside diameter of welch plug to prevent leaks.

  • Page 86: Mikuni Carburetor - Models 290700, 303700, 350700 (Before 951001Xx)

    21. Position bowl drain as shown. 22. Torque screw or solenoid to 45 in. lbs. (5 Nm). Fig. 37 18. Install idle jet (18), plug (19) and gasket (20), Fig. 38. Fig. 40 Mikuni Carburetor Models 290700, 303700, 350700 (Before 951001xx) Check Throttle, Choke Shaft and Body For Wear NOTE: The measurement in Step 1 is taken with the...
  • Page 87 … † ‚ ‡ ˆ Fig. 42 Fig. 44 4. Remove emulsion tube (10), Fig. 45. Replace either shaft if worn. NOTE: If carburetor is equipped with solenoid, remove solenoid seat (9) first, then remove Replace the carburetor if the body is worn or if either emulsion tube.
  • Page 88 NOTE: The top and bottom edges of the throttle Remove Fuel Inlet Body and Seat plate are beveled. Mark throttle plate before The fuel inlet body must be removed before the inlet removing to ensure reinstallation in the seat can be removed. original position.
  • Page 89 Clean Carburetor Install Fuel Inlet Seat and Body 1. Install new inlet seat (1) with chamfered end 1. Disassemble carburetor. down, Fig. 51. 2. Remove and discard all old gaskets, seals and 2. Press in new body (3) using Knockout Pin sealing material.
  • Page 90 NOTE: Use LOCTITE 222 on screw threads. Fig. 55 16. Install emulsion tube (24), Fig. 56, using Screw- driver #19062. Fig. 53 17. If carburetor is equipped with anti-afterfire solenoid, install solenoid seat (25). 18. Install fixed main jet (26) using Screwdriver #19061.

  • Page 91: Nikki Carburetor - Models 351700, 351400, 380700, 380400

    Nikki Carburetor Replace either shaft if worn. Replace the carburetor of the body is worn or if either Models 351700, 351400, 380700, 380400 shaft clearance exceeds 0.010” (0.25 mm) when a new shaft is used. Check Throttle, Choke Shaft and Body For Wear NOTE: The measurement in Step 1 is taken with the Disassemble carburetor off of the intake manifold.
  • Page 92 Fixed Main Jet Sizes ‰ Model 351700 Left (#1) cylinder is equipped with #98 main jet. Š Right (#2) cylinder is equipped with #100 main jet. Model 351400 Left (#1) cylinder is equipped with #94 main jet. Right (#2) cylinder is equipped with #98 main jet. Model 380700 Fig.
  • Page 93 NOTE: If idle mixture screws are equipped with adjustment limiter caps, remove the caps (18) BEFORE removing idle mixture screws, inset, Fig. 65. Fig. 67 Clean Carburetor 1. Disassemble carburetor. 2. Remove and discard all old gaskets, seals and Fig. 65 sealing material.
  • Page 94 Inspect Carburetor 6. Assemble inlet needle (11) to float (10). Install float assembly to carburetor body, Fig. 70. Inspect all parts for wear, cracks, nicks and burrs. Install float hinge pin (12) from throttle lever Inspect float for leaks. Replace damaged parts. (13) side.

  • Page 95: Nikki Carburetor - Models 290400, 303400, 350400 (After 950731Xx)

    Fig. 74 Fig. 72 14. Assemble lower body with main jet plugs (23) 12. Install fixed main jets (20), Fig. 73, plugs and facing throttle shaft side (24) of carburetor. Make washers. sure gasket remains in position, Fig. 75. Tighten screws (22) securely.
  • Page 96 3. Remove float and inlet needle. ‚  Fig. 76 NOTE: The inspection in Step 2 is performed after Fig. 79 the carburetor has been disassembled. If idle mixture screw is equipped with adjustment 2. Inspect throttle shaft and choke shaft for wear limiter cap (9), use a pliers to remove it before (3), Fig.
  • Page 97 8. The top and bottom edges of the throttle plate are beveled. Mark throttle plate (11), Fig. 82 Ò Ò Ò Ò before removal to ensure reinstallation in the original position. 9. Remove throttle shaft (13) and spacer (14). 10. Remove throttle shaft seal (12). Ò...
  • Page 98 Inspect Carburetor NOTE: Use LOCTITE 222 on screw threads (10). Inspect all parts for wear, cracks, nicks and burrs. Inspect float for leaks. Replace damaged parts. † Assemble Carburetor ‡ When assembling carburetor, use new seals and gaskets. 1. Install new transitional hole welch plug (1), Š...
  • Page 99 NOTE: Use brass inlet needle for fuel pump as shown in Fig. 92. This allows the weight of the carburetors. Use aluminum inlet needle for float to close the inlet needle. gravity feed carburetors. 3. The float height is the dimension between the top flat area of the float just before the radius (23) and the machined surface of the carburetor (22).

  • Page 100: Mikuni Carburetor - Models 290400, 303400, 350400 (Before 950801Xx)

    Check Throttle, Choke Shaft and Body For Wear NOTE: The measurement in Step 1 is taken with the carburetor off of the intake manifold. 1. Lay carburetor on 1/8” (3 mm) raised flat surface (1). Use a feeler gauge (2) to check throttle and choke shaft clearance as shown in Fig.
  • Page 101 If equipped, remove adjustment limiter cap (14) with ‚ a pliers (inset) before removing idle mixture screw, Fig. 101. ƒ 8. Remove idle mixture screw (16) and spring.  9. Remove fuel bowl drain screw (15) and spring. „ Fig. 98 3.
  • Page 102 ƒ † Ò Ò Ò Ò Ò Ò Ò Ò … „ Ò Ò Fig. 105 Fig. 103 This completes carburetor disassembly procedure. Clean Carburetor Remove Fuel Inlet Body and Seat 1. Disassemble carburetor. The fuel inlet body must be removed before the inlet 2.
  • Page 103 Inspect Carburetor 8. Assemble spacer (9) onto choke shaft. Inspect all parts for wear, cracks, nicks and burrs. 9. Insert spring and check ball (11) in to spring Inspect float for leaks. Replace damaged parts. pocket. Compress with a small round punch. 10.
  • Page 104 CAUTION: DO NOT press on float to adjust. Fig. 110 18. Assemble inlet needle retainer (21) to inlet needle (22). Assemble to float (23), Fig. 111. Fig. 112 19. Install float (23) and needle to upper carburetor 21. Place new gasket (31) on lower carburetor body. body.

  • Page 105: Nikki Carburetor - Model 540000

    Model 540000 General Information The Vanguardt Model 540000 OHV V-Twin utilizes a fixed jet, two barrel, side draft, flo-jet carburetor. Except for idle speed, the carburetor is non-adjustable. The carburetor incorporates a fuel shut-off (anti-afterfire) solenoid that controls fuel flow to the fuel metering system. The solenoid is controlled by the ignition switch.
  • Page 106 Remove Carburetor from Manifold Remove carburetor gaskets (2) and spacer (1), Fig. 114. Discard carburetor gaskets. ‚  ‚ Fig. 116 ‚ Replace either shaft if worn. Replace the carburetor if the body is worn or if either shaft clearance exceeds 0.010” (0.25 mm) when a new shaft is used.
  • Page 107 … „ † ‡ ˆ Fig. 121 Fig. 118 11. Mark throttle plates (16), Fig. 122, before 7. Remove cover plate (10). Discard gasket (11), removal so they will be re-installed in the original Fig. 119. position. Sides of throttle plate are beveled. Š...
  • Page 108 NOTE: Parts containing rubber, such as seals, O-rings, inlet needles, seats or pump diaphragms should not be placed in ‚ commercial carburetor cleaner. Do not leave non-metallic parts (plastic, nylon, Minlon, etc.), commercial carburetor cleaner more than 15 minutes.  CAUTION Fig.
  • Page 109 † ‰ Š ‡ Fig. 126 Fig. 128 8. Assemble bowl gasket (9) to body. 9. Install main jet, according to engine model. 10. Install the float bowl assembly to the carburetor 6. Install emulsion tube body (8) with new gasket body.

  • Page 110: Aisan Carburetor - Model 610000

    Model 610000 General Information The Vanguardt Model 610000 OHV V-Twin utilizes a fixed jet, two barrel, side draft, flo-jet carburetor. The carburetor incorporates a fuel shut-off (anti-afterfire) solenoid that controls fuel flow to the fuel metering system. The solenoid is controlled by the ignition switch.
  • Page 111 Disassemble Carburetor ‰ ‡ ˆ Š 1. Remove four screws (1) and float bowl (2), Fig. 130. Discard gasket. 2. Use 13 mm thin profile wrench to remove fuel solenoid (3) from float bowl. Discard gasket. † … ‚  ‰...
  • Page 112 NOTE: Use LOCTITE 222 on screw threads. CAUTION 4. Assemble inlet needle to float. Install float, Fig. 133. 5. Assemble bowl gasket to groove in body. AVOID EYE INJURY! • Wear eye protection when using com- NOTE: The tab on the float bowl gasket (1) goes in pressed air.

  • Page 114: Governor

    Section 5 Governor Page GENERAL INFORMATION ............GOVERNOR CONTROLS .
  • Page 115 Drain oil and remove engine from equipment. Governed Idle Remove spark plugs. Remove valve covers. OHV V-Twin engines equipped for manual friction or Compress valve springs and remove push rods. remote control have a governed idle system, Fig. 3. 1. Disconnect governor link and spring (1) at A throttle restrictor maintains the engine speed carburetor, Fig.
  • Page 116 3. Loosen governor lever nut (3). 4. Remove governor lever (2) from shaft.   ‚ „ ƒ Fig. 7 ‚ ƒ Remove Governor Shaft 1. Remove cotter pin (3) and collar (2). Discard Fig. 5 cotter pin, Fig. 8. 5.
  • Page 117  ‚ Ô Ô Ô Ö Ö Ô Ô Ö ƒ Ô Ô Ô Ö Ö Ô Ô Ö Ö Ö Ô Ô ‚ Ö Ö  ƒ Fig. 9 Fig. 11 2. Insert proper seal protector through oil seal. Install Governor Shaft 3.
  • Page 118 2. If necessary, remove the governor gear (1) from … the crankcase cover with two screwdrivers (3). Remove the washer from under the governor gear. „ ‚  ƒ † ‡ ƒ Fig. 13 9. Perform governor adjustments, see Trouble- shooting, Section 2.
  • Page 119 3. Replace the oil seal (6, under the washer). ƒ Replace worn or damaged components. „ NOTE: Inspect the crank and the crank bushings. If … the bushings are damaged or worn replace the cylinder block. † ‡ ‚ Install Governor Crank Fig.

  • Page 120: Cylinder Heads And Valves

    Section 6 Cylinder Heads and Valves Page CYLINDER HEAD SERVICE ............Remove Cylinder Head .

  • Page 121: Cylinder Head Service

    PARTS IDENTIFICATION each valve. The redesigned cylinder head, gasket and rocker arm assembly will not interchange with Compression testing information and procedure is previous cylinder heads. The new cylinder head may described in Section 2 – TROUBLESHOOTING. be used on earlier V-Twins, but only as a complete Fig.

  • Page 122: Disassembly

    5. Remove intake and exhaust valves. „  ‚  ‚ ƒ ƒ Fig. 5 Fig. 7 3. Remove head bolts (5, 6, 7, 8) and cylinder head, Fig. 6. Discard cylinder head gasket. 6. Remove and discard valve stem seals, Fig. 8. NOTE: Engines manufactured before 940501xx were equipped with sealing washers under cylinder head bolts (5) and (6).
  • Page 123 3. Use Reamer Pilot Guide #19345 (5) and Finish • CAUTION: Do not resurface cylinder head Reamer #19444 (6) to ream new valve guide, mounting surfaces. Fig. 13. 2. Check valve guide bushings for wear using Plug a. Use Stanisol or kerosene to lubricate Gauge (2) #19382, Fig.

  • Page 124: Assembly

    1. Measure valve stem diameter approximately NOTE: Lightly coat valve stems with Valve Guide 1-1/2” (38 mm) from end of valve, Fig. 15. Lubricant #93963 before installing valves. Be sure valve guide lubricant is not on valve Replace valve if stem diameter is less than 0.233” face, seat or end of valve stem.

  • Page 125: Install Cylinder Head

    Install Cylinder Heads Early Style 1. Install cylinder head with NEW gasket, Fig. 20. NOTE: Rocker shaft support (3) holes are offset. Install with holes facing ends of rocker shaft, Fig. 22.  ƒ 1. Lubricate rocker arms (4) and shaft (2) with clean engine oil.

  • Page 126: Starters

    Section 7 Starters Page GENERAL INFORMATION ............REWIND STARTER IDENTIFICATION .

  • Page 127: General Information

    Fig. 4 or the roll pin retainer, Fig. 5. The engine. Three starter motors are used on steel pinion starter drive is shown in Fig. 6. When the Vanguard V-Twin engines, Figs. 1-3. starter motor is activated, the pinion gear should Nylon Pinion engage the flywheel ring gear and crank the engine.

  • Page 128: C-Ring Style

    C-Ring Style ‚ Disassemble  ƒ CAUTION „ PREVENT EYE INJURY! … • Wear eye protection when removing C-ring. Fig. 8 1. Place the counterbored side of C-ring Remover 4. Place C-ring (8) over chamfered end of shaft. #19436 (2) over retainer. Align drive pins (1) with Align one of the slots (7) of C-ring Installer open end of C-ring, Fig.

  • Page 129: Steel Pinion Style

    Assemble 3. Assemble lower spring retainer with OPEN END 1. Assemble clutch drive (5) to starter shaft. Rotate clutch until it drops into place, Fig. 11. 4. Install spring. 2. Install pinion gear (4) with beveled side of teeth 5. Install upper spring retainer with OPEN END UP. 6.

  • Page 130: Inspect Armature Commutator

    4. Remove end cap and brush retainer with ‡ ˆ brushes. Replace end cap if bushing is worn or ‰ † damaged. Š ƒ „ ƒ ‚   … Fig. 15 … Inspect Armature Commutator Fig. 13 The armature commutator shown in Fig. 16 (A) can be cleaned with fine sandpaper.

  • Page 131: Replace Brushes

    ƒ   ‚ ƒ ‚ Fig. 17 Fig. 20 Assemble End Cap Replace Brushes NOTE: When all parts have been inspected, Three different brush end caps are used. Refer to lightly lubricate bearings in both end caps Fig. 18 for radial flat coil spring end caps. with #20 oil.

  • Page 132: Assemble Armature

    Brush retainers can be made from Part #26634 control wire or similar material. The retainer is U ‡ shaped, with two legs 1/2” (13 mm) high (2), 3/4” (19 mm) long (3), Fig. 22, inset. 1. Install brush spring and brush into holder. 2.

  • Page 133: Install Drive End Cap

    STARTER MOTOR SERVICE 1. Push down on armature and brush end cap. Models 540000, 610000 2. Slide starter housing (1) over armature (2), aligning notch with insulated terminal. Remove Starter Solenoid NOTE: Use care to prevent damage to magnets in 1.

  • Page 134: Pinion Gear

    Pinion Gear 5. Remove armature and pinion gear with drive lever from drive end cap, Fig. 33. Pinion gear replacement requires complete starter motor disassembly. A thorough inspection of all components should be performed at that time. Disassemble Starter For ease of disassembly and assembly, clamp drive end housing in a vise as shown, Fig.
  • Page 135 Clean and inspect helix. If helix is damaged, replace The following test will be made with the meter in the starter. Inspect bearing journals on armature shaft (Diode Test) Position. for wear or damage. If bearing journals are worn or 1.
  • Page 136 ‚  ƒ Fig. 40 Assemble Pinion Gear 1. Lubricate helix with a light coat of grease. Assemble pinion gear and clutch. 2. Assemble new retainer to shaft. 3. Install new C-ring. Fig. 42 4. Pry up on retainer until C-ring snaps into groove in retainer, Fig.

  • Page 137: Ring Gear Service

    8. Install end cap, Fig. 47. Torque thru bolts to 70 in. lbs. (8 Nm). † † ‡ ‡ Fig. 44 4. Insert brushes into brush holder, Fig. 45. Fig. 47 5. Compress springs with needle nose pliers and insert spring behind brushes. 9.

  • Page 138: Rewind Starter Identification

    REWIND STARTER IDENTIFICATION Two rewind starters are used on V-Twin engines. The rewind starter components (including the starter and cup) are NOT INTERCHANGEABLE between starters. Figure 49 shows how to identify the rewind starters. Current Style Early Style ‚ ‚ ...

  • Page 139: Replace Rope

    Replace Rope 4. Rotate pulley CLOCKWISE just until rope hole in pulley (2) is in line with starter housing eyelet (1). Remove Rope 5. Hold pulley in this position. 1. Pull rope out partially. Tie a temporary knot (4), Fig. 51. 2.

  • Page 140: Replace Pulley And Spring - Current Style

    5. Carefully lift out pulley with spring, Fig. 57. ‚ ƒ „ Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó...

  • Page 141: Replace Pulley And Spring - Early Style

    Assemble Pulley To Housing 2. Install retainer making sure that slots (4) in retainer (6) engage tabs (7) on pulley, Fig. 63. 1. Lay starter housing on work bench. 3. Hold retainer down, compressing dog springs 2. Assemble starter pulley (1) and spring assembly and install retainer screw (5).
  • Page 142 Inspect Spring, Starter Housing and Pulley  Inspect pulley for cracks, rough edges (1) or burrs in ‚ pulley groove, wear on spring cup lugs (2), and wear on center hole (3), Fig. 67. Replace pulley if ƒ damaged or worn. „...

  • Page 143: Install Rewind Starter

    2. Note location of spring tab (5) and location of spring anchor (4) on center post of starter housing. 3. Lower starter housing onto pulley and spring as- sembly, Fig. 70. Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó Ó ‚...

  • Page 144: Lubrication Systems

    Section 8 Lubrication Systems Page CRANKCASE BREATHER IDENTIFICATION ......... CRANKCASE BREATHER SERVICE .
  • Page 145 GENERAL INFORMATION Crankcase Breather Identification Briggs & Stratton Vanguardt OHV V-Twins use a Vanguardt engines utilize a breather valve to full pressure lubrication system with an oil filter. The control and maintain a vacuum in the crankcase. gear driven oil pump (1) draws oil from a screened The breather vents crankcase vapors through the air oil pickup (2) in the sump and pumps the oil through cleaner.
  • Page 146 CRANKCASE BREATHER SERVICE ‚ ƒ Models 290000 – 351000 Remove the air cleaner assembly. Remove breather assembly (1). Discard gasket (2), Fig. 5.   Fig. 7 Install Reed Valve Breather Ó Ó Ó Ó Ó Ó Ó Ó Ó 1.
  • Page 147 Model 380000 Remove two screws. Separate breather assembly from valve cover, Fig. 10. Fig. 12 Fig. 10 Install Breather 1. Assemble reed valve and reed stop to breather body, Fig. 13. Tighten screws securely. Checking Breather NOTE: Holes in reed and reed stop are offset. 1.
  • Page 148 Oil Pump Models 540000, 610000 1. Remove two screws (6) and breather cover (5), Inspect Fig. 15. Inspect pump drive gear (2) for worn or chipped 2. Lift off the outer baffle (4). teeth. Inspect inner pump rotor (4), outer pump rotor (1), housing (3) and crankcase cover or sump for 3.
  • Page 149 Models 540000, 610000 For proper sealing on these models, the oil fill cap (5) has an O-ring, the dipstick has a grommet (6), Fig. 18. NOTE: The oil dipstick tube (7) is not removeable/ serviceable on these models. If damaged replace the crankcase cover.

  • Page 150: Cylinders And Crankcase Covers/Sumps

    Section 9 Cylinders and Crankcase Covers/Sumps Page CYLINDERS ..............Inspect and Measure .

  • Page 151: Cylinders

    CYLINDERS ‚ ƒ „  Inspect and Measure 1. Check cylinder for cracks, stripped threads or broken fins. Check cylinder bores for damage or scoring. 2. Check cylinder head mounting surface for dis- Fig. 2 tortion with a straight edge, Fig. 1. Resizing Cylinder Replace the cylinder if the mounting surfaces are distorted more than 0.004”...

  • Page 152: Finishing

    Finishing NOTE: Recondition the cylinder bores to restore the crosshatch finish whenever new piston Finishing stones are used after the cylinder bore has rings are installed to a cylinder that is within been resized to within 0.0015” (0.04 mm) of the specification.

  • Page 153: Engine Bearings

    ENGINE BEARINGS Mag Bearing – After 970430xx  Check 1. Check magneto bearing for damage. Check for wear at several locations using plug gauge #19219 (1) or appropriate measuring tools, Fig. 5. If plug gauge is not available see reject dimension in Section 13.

  • Page 154: Pto Ball Bearing

    Insert Bushing Driver #19349 into bearing from oil seal side. Place a reference mark on driver to … „ indicate proper depth of bushing when installing new bearing, as shown, Fig. 6. Remove The magneto bearing has a roll pin installed in the oil gallery to prevent the bearing from turning.

  • Page 155: Pto Plain Bearing

    The following tools are recommended to replace the 3. Insert screw (2) and washer (1) through pilot (3) ball bearing, Fig. 15. and thread into support (5). Tighten screw until bearing is seated. (1) Washer #224061 4. Use Cylinder Support #19227 and press oil seal (2) Puller Screw #19318 until flush with crankcase cover.

  • Page 156: Crankshafts And Camshafts

    Section 10 Crankshafts and Camshafts Page INSPECT CAMSHAFT ............. . INSPECT CRANKSHAFT .

  • Page 157: Inspect Crankshaft

    INSPECT CRANKSHAFT Complete instructions are included with undersize connecting rods. Inspect crankshaft threads (1) and keyways (2, 8), Fig. 1. Replace crankshaft if threads or keyways are damaged or worn. Check magneto (3) and PTO (7) journals for scoring. Measure journals for wear. Replace crankshaft if journals are scored, or worn past reject sizes listed in Section 13.
  • Page 158 INSPECT CAMSHAFT Inspect gear teeth (4), lobes (9, 10), compression release balls (7) and camshaft bearing journals (6, 11) for wear and nicks, Fig. 4. ‚ Camshaft journal and lobe reject sizes are shown in specifications page in Appendix. Replace cam gear if ...

  • Page 160: Pistons, Rings And Connecting Rods

    Section 11 Pistons, Rings and Connecting Rods Page ASSEMBLE PISTON AND CONNECTING ROD ........ASSEMBLE RINGS TO PISTON .

  • Page 161: Disassemble

    GENERAL INFORMATION ‚ Install new piston rings whenever the engine is disassembled for major servicing or overhaul, providing that cylinder bores are within specification. 1. Remove any carbon or ridge at the top of the cylinder bore. This will prevent breaking the rings when removing the piston and connecting rod from the engine.

  • Page 162: Assemble Piston And Connecting Rod

    Models 540000, 610000 • Top Compression Ring – 0.030” (0.76 mm) • Center Compression Ring – 0.030” (0.76 mm) • Oil Rings – 0.040” (1.0 mm) Fig. 6 Check connecting rod bearings, Fig. 7. Î Î Î Î NOTE: Undersize (0.020”) connecting rods are available for use on a reground crankpin journal on some engines.

  • Page 163: Assemble Rings To Piston

    Assemble Piston Rings to Piston Install rings in order shown, Fig. 10. Use Piston Ring Expander, #19340 when installing center (2) and top (1) compression rings. 1. Install oil ring expander (4). a. Install lower scraper ring (5). b. Install upper scraper ring (3). Fig.

  • Page 164: Engine Assembly

    Section 12 Engine Assembly Page ..............ENGINE ASSEMBLY .

  • Page 165: Engine Assembly

    ENGINE ASSEMBLY NOTE: The words “OUT-1” (5) on #1 connecting rod must be facing PTO side of engine (6). Install Crankshaft „ … Lubricate mag bearing and lips of oil seal with engine ƒ oil. Install crankshaft, Fig. 1. † Fig.

  • Page 166: Install Oil Pump

    3. Align timing marks on camshaft and crankshaft timing gear. Install camshaft, Fig. 5. 4. Assemble governor spool (2) to camshaft (except Models 540000, 610000).  a. Install new O-ring (3) in cylinder. b. Make sure that spool engages flyweights and slot on spool fits over locating pin (1).

  • Page 167: Install Cylinder Heads

    Crankshaft end play is adjusted by adding or 2. Assemble rocker studs (1), rocker arm supports removing a thrust washer. Thrust Washer Kit and rocker arms (3) to cylinder head, Fig. 11. #807625 contains shims with the following thickness; 3. Torque studs to 100 in. lbs. (11 Nm). 0.039”...

  • Page 168: Install Starter Motor, Breather, Alternator

    ‚   ‚ ƒ ƒ Fig. 13 Fig. 15 Install Flywheel 2. Install valve covers with new gaskets and valve cover seals (6), Fig. 14. Torque nuts (7) to 25 in. lbs. (3 Nm). All models except Engines with POWERLINKt NOTE: Models 540000, 610000 –...

  • Page 169: Flywheel - Powerlinke

    Install Flywheel – Models 350000, 380000 Engines with PowerLinkt 1. Install washer and flywheel nut. 2. Assemble Flywheel Holder #19321 (2) to NOTE: Before installing flywheel make sure the fly- retainer, Fig. 17. wheel magnets are free of debris. 3. Use a torque wrench (1) and 30 mm socket (3) to torque flywheel nut to 125 ft.

  • Page 170: Install Armatures

    Install Armatures 3. Assemble governor lever (3) to governor shaft. DO NOT tighten nut at this time. 1. Assemble armature to engine, Fig. 20. 4. Install governor control bracket (2). Torque 2. Install ground wire onto tab terminal on screws to 140 in. lbs. (16 Nm). armatures.

  • Page 171: Horizontal Crankshaft

    2. Assemble carburetor onto mounting studs, Fig. 24.  ƒ  ‚ „ Fig. 26 ‚ 3. Connect choke link (7) to choke lever and install choke control bracket (5), single barrel Fig. 24 carburetor, Fig. 27, two barrel carburetor, Fig.
  • Page 172 Ñ Ñ Ñ Ñ † ‚ ƒ  „ ‡ ˆ ‰ Š Fig. 31 Fig. 29 a. Be sure locating pin (2) in spacer fits in Models 351400, 380400, 540000, 610000 recess (4) in manifold. 1. Assemble intake elbow (1) and air cleaner elbow b.

  • Page 173: Install Blower Housing

    3. Assemble choke link (6) to choke lever, Fig. 33. 10. Assemble choke link (13) to carburetor and choke lever. Install choke bracket (15). Torque screws to 65 in. lbs. (7 Nm). 11. Install air cleaner elbow support. Torque screw to 65 in.

  • Page 174: Horizontal Crankshaft

    4. Install breather deflector (4) and three screws 5. Torque nuts and screws to 65 in. lbs. (7 Nm). (3). Torque nuts and screws to 65 in. lbs. Make sure air inlet tube is installed correctly to air (7 Nm). cleaner base.
  • Page 175 ‚  ƒ ‚  „ ƒ ˆ ‡ … „ † Fig. 41 Fig. 43 3. Install breather deflector (2) and two screws (3). Do not tighten at this time. 4. Install two air cleaner support screws (4). Torque screws to 65 in.

  • Page 176: Final Engine Assembly

    Final Engine Assembly 1. Loosen governor lever nut. Push on governor lever (1) until throttle is wide open. • Install muffler and exhaust manifold. Torque to 150 in. lbs. (17 Nm). CAUTION: Do not bend governor link or distort governor lever. NOTE: Models 540000, 610000 torque screws to 180 in.
  • Page 178 Section 13 Engine Specifications Page ENGINE SPECIFICATIONS ............Models 290000, 300000 .

  • Page 179: Engine Specifications

    Models 290000, 300000 Common Specifications NOTE: All dimensions in Inches (Millimeters) Armature Air Gap ..........0.008 –...
  • Page 180 Torque Values Description Torque Air Cleaner Mounting ............90 in.

  • Page 181: Model 350000

    Model 350000 Common Specifications NOTE: All dimensions in Inches (Millimeters) Armature Air Gap ..........0.008 –...
  • Page 182 Torque Values Description Torque Air Cleaner Mounting ............90 in.

  • Page 183: Model 380000

    Model 380000 Common Specifications NOTE: All dimensions in Inches (Millimeters) Armature Air Gap ..........0.008 –...
  • Page 184 Torque Values Description Torque Air Cleaner Mounting ............90 in.

  • Page 185: Models 540000, 610000

    Models 540000, 610000 Common Specifications NOTE: All dimensions in Inches (Millimeters) Armature Air Gap ..........0.005 –...
  • Page 186 Torque Values Description Torque Air Cleaner Mounting ............190 in.

  • Page 187: Honing Fixture

    Vanguardt Engines – Honing Fixture 10” (254 mm) 3” (76 mm) 3-1/4” (83 mm) 1-7/8” (48 mm) 6-11/32” (161 mm) 8-9/16” (217 mm) 10” (254 mm) 2” (51 mm) 8-5/32” (207 mm) 13/32” Thru Hole (4) (10 mm) CLAMP THIS END IN VISE Material: Wood 2”...

  • Page 188: Starter Motor Support Block

    Starter Motor Support Block d. 2” (50.8 mm) e. 10” (254 mm) A starter motor support block can be made from 1” (25.4 mm) stock 1” (25.4 mm) thick as shown in Fig. 1. The dimensions for the block are: g.

  • Page 189: Tables

    FUEL SYSTEM IDENTIFICATION DIODE FAILURE DIAGNOSIS Model Fuel System Color Switch ON Switch OFF Cause Type Code Engine Runs on Shuts Off OK 1 Closed 290400 Gravity Yellow Only 1 Cylinder Diode 290400 Pump White Engine Runs on Only 1 Cylinder 1 Open Both Cylinders Shuts Off...

  • Page 190: Drill Size - Decimal Equivalents

    Drill Size – Decimal Equivalent (Inches) 0.040 9/64 0.1406 E, 1/4 0.250 0.041 0.144 0.257 0.042 0.147 0.261 0.043 0.1495 17/64 0.2656 0.0465 0.152 0.266 0.052 0.154 0.272 0.055 5/32 0.1562 0.277 0.0595 0.157 0.281 1/16 0.0625 0.159 9/32 0.2812 0.0635 0.161 0.290...

  • Page 191: English To Metric Conversions

    English to Metric Conversion Table Fraction Decimal Fraction Decimal 1/64 0.0156 0.396 33/64 0.5156 13.096 1/32 0.0313 0.795 17/32 0.5313 13.495 3/64 0.0469 1.191 35/64 0.5469 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.0781 1.984 37/64 0.5781 14.684 3/32 0.0938 2.383 19/32...

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